HAIRPIN COIL FORMING APPARATUS

Abstract

A hairpin coil forming apparatus configured to 3D-form a head portion of a 2D-formed I-shaped coil material, the hairpin coil forming apparatus includes a frame, a first mold disposed on a first side of the frame to form the head portion of the coil material into a predetermined shape, a second mold disposed on a second side of the frame to secondarily form the head portion of the pre-formed coil firstly formed by the first mold, a first coil transfer unit disposed in a process work area to transfer the coil material to the first mold, and a second coil transfer unit disposed on the frame to transfer the pre-formed coil from the first mold to the second mold.

Claims

1. A hairpin coil forming apparatus configured to 3D-form a head portion of a 2D-formed I-shaped coil material, the hairpin coil forming apparatus comprising: a frame; a first mold disposed on a first side of the frame to form the head portion of the coil material into a predetermined shape; a second mold disposed on a second side of the frame to secondarily form the head portion of the pre-formed coil firstly formed by the first mold; a first coil transfer unit disposed in a process work area to transfer the coil material to the first mold; and a second coil transfer unit disposed on the frame to transfer the pre-formed coil from the first mold to the second mold.

2. The hairpin coil forming apparatus of claim 1, wherein the first mold comprises: a first lower holder fixed to the frame; a first lower die disposed in the first lower holder; a first upper holder which is disposed to be movable in a vertical direction by operation of a first driver on a first mount block disposed on the first lower holder; and a first upper die disposed in the first upper holder at a position corresponding to the first lower die.

3. The hairpin coil forming apparatus of claim 2, wherein the first lower die includes a pair of first lower forming steels which are fixed to the first lower holder, and wherein the first upper die includes a pair of first upper forming steels that are fixed to the first upper holder.

4. The hairpin coil forming apparatus of claim 2, wherein the first mold further comprises a first coil guider disposed on the first lower holder.

5. The hairpin coil forming apparatus of claim 4, wherein the first mold further comprises a head portion clamper disposed on the first upper die to clamp the head portion of the coil material disposed on the first lower die.

6. The hairpin coil forming apparatus of claim 4, wherein the first coil guider comprises a pair of first guide blocks fixed at a predetermined interval to the first lower holder to guide the leg portion of the coil material.

7. The hairpin coil forming apparatus of claim 5, wherein the head portion clamper comprises at least one head portion clamping block disposed on the first upper die, elastically supported by a spring and movable in an up and down direction.

8. The hairpin coil forming apparatus of claim 7, wherein the at least one head portion clamping block is disposed on a guide rod fixed to the inside of the first upper die to be movable in the vertical direction by a predetermined stroke.

9. The hairpin coil forming apparatus of claim 1, wherein the second mold comprises: a second lower holder fixed to the frame; a second lower die disposed in the second lower holder; a second upper holder disposed to be movable in the vertical direction by operation of a second driver on a second mount block disposed on the second lower holder; and a second upper die disposed in the second upper holder at a position corresponding to the second lower die.

10. The hairpin coil forming apparatus of claim 8, wherein the second lower die includes a pair of second lower forming steels which are fixed to the second lower holder, and wherein the second upper die includes a pair of second upper forming steels fixed to the second upper holder.

11. The hairpin coil forming apparatus of claim 8, wherein the second mold further comprises a second coil guider disposed on the second lower holder.

12. The hairpin coil forming apparatus of claim 10, wherein the second mold further comprises a leg portion clamper which is disposed vertically movably on the second upper holder to clamp the leg portion of the pre-formed coil disposed on the second coil guider.

13. The hairpin coil forming apparatus of claim 11, wherein the second coil guider comprises a pair of second guide blocks fixed at a predetermined interval to the second lower holder to guide the leg portion of the pre-formed coil.

14. The hairpin coil forming apparatus of claim 12, wherein the leg portion clamper comprises: a leg portion clamping block which is disposed to move in the vertical direction by operation of a clamp cylinder disposed in the second upper holder; and a leg pusher that extends protrudingly from the lower portion of the leg portion clamping block to press the leg portion between the second guide blocks.

15. The hairpin coil forming apparatus of claim 1, wherein the first coil transfer unit comprises: a first horizontal moving member which is disposed to move in the horizontal direction by operation of a first actuator at a position corresponding to the first mold; a first vertical moving member disposed in the first horizontal moving member to be configured to move in the vertical direction by operation of a second actuator; and a first coil gripper disposed on the first vertical moving member to grip and un-grip the coil material by operation of a first gripping cylinder.

16. The hairpin coil forming apparatus of claim 15, wherein the first horizontal moving member 63 is slidably connected to a first guide device disposed on a base plate along the horizontal direction.

17. The hairpin coil forming apparatus of claim 1, wherein the second coil transfer unit comprises: a second horizontal moving member which is disposed to move in the horizontal direction by operation of a third actuator along the section between the first mold and the second mold; a second vertical moving member disposed in the second horizontal moving member to be configured to move in the vertical direction by operation of a fourth actuator; and a second coil gripper disposed on the second vertical moving member to grip and un-grip the pre-formed coil by operation of a second gripping cylinder.

18. The hairpin coil forming apparatus of claim 17, wherein the second coil transfer unit further comprises a turning cylinder disposed on the second vertical moving member and connected to the second coil gripper.

19. The hairpin coil forming apparatus of claim 17, wherein second horizontal moving member is slidably connected to a third guide device disposed on the frame 10 along the horizontal direction and moved in the horizontal direction along the third guide device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] These drawings are intended for reference in explaining exemplary various disclosure of the present disclosure, and therefore, the technical ideas of the present disclosure should not be construed as being limited to the accompanying drawings.

[0031] FIG. 1 is a perspective view exemplarily illustrating a hairpin coil forming apparatus according to various disclosure.

[0032] FIG. 2 is a top plan view exemplarily illustrating a hairpin coil forming apparatus according to various disclosure.

[0033] FIG. 3 is a drawing showing forming processes of an I-shaped hairpin coil formed by a hairpin coil forming apparatus according to various disclosure.

[0034] FIG. 4 is a perspective view exemplarily illustrating a first mold applied to a hairpin coil forming apparatus according to various disclosure.

[0035] FIG. 5 is a front view exemplarily illustrating a first mold applied to a hairpin coil forming apparatus according to various disclosure.

[0036] FIG. 6 is a side view showing a first mold applied to a hairpin coil forming apparatus according to various disclosure.

[0037] FIG. 7 is a partially cut-away perspective view exemplarily illustrating a head clamper of a first mold applied to a hairpin coil forming apparatus according to various disclosure.

[0038] FIG. 8 is a perspective view exemplarily illustrating a second mold applied to a hairpin coil forming apparatus according to various disclosure.

[0039] FIG. 9 is a front view exemplarily illustrating a second mold applied to a hairpin coil forming apparatus according to various disclosure.

[0040] FIG. 10 is a side view exemplarily illustrating a second mold applied to a hairpin coil forming apparatus according to various disclosure.

[0041] FIG. 11 is a side view exemplarily illustrating a hairpin coil forming apparatus according to various disclosure.

[0042] FIG. 12 is a perspective view exemplarily illustrating a first coil transfer unit applied to a hairpin coil forming apparatus according to various disclosure.

[0043] FIG. 13 is a side view exemplarily illustrating a first coil transfer unit applied to a hairpin coil forming apparatus according to various disclosure.

[0044] FIG. 14 is a perspective view exemplarily illustrating a second coil transport unit applied to a hairpin coil forming apparatus according to various disclosure.

[0045] FIG. 15 is a front view exemplarily illustrating a second coil transfer unit applied to a hairpin coil forming apparatus according to various disclosure.

[0046] FIG. 16 and FIG. 17 are drawings for explaining the operation of a hairpin coil forming apparatus according to various disclosure.

DESCRIPTION OF SYMBOLS

TABLE-US-00001 1: hairpin coil 3: coil material 4a, 6a: head portion 4b, 6b: leg portion 10: frame 10a: floor 20: first mold 21: first lower holder 23: first coil guider 24: first guide block 25: first lower die 26: first lower forming steel 27: first upper holder 28: first driver 29: first upper die 31: head portion clamper 33: first mount block 35: first upper forming steel 37: spring 38: guide rod 39: head portion clamping block 40: second mold 41: second lower holder 43: second coil guider 44: second guide block 45: second lower die 46: second lower forming steel 47: second upper holder 48: second driver 49: second upper die 51: leg portion clamper 52: clamp cylinder 53: second mount block 55: second upper forming steel 57: leg portion clamping block 59: leg pusher 60: first coil transfer unit 61: base plate 63: first horizontal moving member 65: first vertical moving member 67: first coil gripper 68: first gripping cylinder 69: first actuator 71: first servo motor 72: first guide device 73: second actuator 74: second servo motor 75: second guide device 77: first gripping finger 80: second coil transfer unit 81: second horizontal moving member 83: second vertical moving member 85: second coil gripper 86: second gripping cylinder 87: turning cylinder 89: third actuator 91: third servo motor 92: third guide device 93: fourth actuator 94: operation cylinder 97: second gripping finger 100: hairpin coil forming apparatus

[0047] The drawings referenced above are not necessarily to scale, but should be understood as presenting rather simplified representations of various exemplary features illustrating the basic principles of the present disclosure. For example, predetermined design features of the present disclosure, including dimensions, direction, position, and shape, will be determined in part by the intended application and usage environment.

DETAILED DESCRIPTION

[0048] Hereinafter, with reference to the appended drawings, various disclosure of the present disclosure will be described in detail so that a person having ordinary skill in the art to which an exemplary embodiment of the present disclosure pertains can easily practice the present disclosure. As those skilled in the art would realize, the described exemplary various disclosure may be modified in various different ways, all without departing from the spirit or scope of the present disclosure.

[0049] To clearly explain an exemplary embodiment of the present disclosure, parts irrelevant to the description are omitted, and the same reference numerals are used for identical or similar components throughout the specification.

[0050] Furthermore, the size and thickness of each component shown in the drawings are arbitrarily shown for convenience of explanation, so that the present disclosure is not necessarily limited to what is shown in the drawings, and the thickness is shown by enlarging it in order to clearly express various parts and areas.

[0051] The terminology used herein is for describing various disclosure and is not intended to limit the present disclosure. As used herein, the singular form is intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0052] It should also be understood that the terms comprises and/or comprising as used herein indicate the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, components, and/or groups thereof.

[0053] And, as used herein, the term connected indicates a physical relationship between two components in which the components are directly connected to each other or indirectly connected through one or more intermediary components.

[0054] Additionally, in the present specification, the term operably connected or similar terms means that at least two members are directly or indirectly connected to each other to be capable of transmitting power. However, two operatively connected members do not always rotate at the same speed and in the same direction.

[0055] Furthermore, as used herein, the terms vehicle, vehicular, automobile or other similar terms used herein generally include passenger automobiles, including passenger cars, sports utility vehicles (SUVs), buses, trucks, and various commercial vehicles, which may include hybrid automobiles equipped with high-voltage batteries, electric automobiles, hybrid electric vehicles, electric vehicle-based Purpose Built Vehicles (PBVs), and hydrogen-powered vehicles (also commonly referred to by those skilled in the art as hydrogen electric vehicles).

[0056] Hereinafter, various disclosure of the present disclosure will be described in detail with reference to the appended drawings.

[0057] FIG. 1 is a perspective view exemplarily illustrating a hairpin coil forming apparatus according to various disclosure, and FIG. 2 is a top plan view exemplarily illustrating a hairpin coil forming apparatus according to various disclosure.

[0058] Referring to FIG. 1 and FIG. 2, the hairpin coil forming apparatus 100 according to various disclosure may be applied to a process of forming hairpin type stator coils wound around a stator core into a predetermined shape among processes for manufacturing a stator of a drive motor.

[0059] The hairpin winding type stator may be applied to environment-friendly vehicles that obtain driving torque with electrical energy, such as drive motors for hybrid vehicles and/or electric vehicles. Here, the stator coils of the hairpin type may be named conductor coils, segment coils or flat coils.

[0060] In one exemplar embodiment of the present disclosure, the stator coils may include U-shaped stator coils formed into a U-shaped hairpin type and I-shaped stator coils formed into an I-shaped hairpin type (hereinafter, referred to as hairpin coil 1).

[0061] The hairpin coil 1 may be formed into an I-shaped hairpin type by the coil forming device 100 according to various disclosure.

[0062] FIG. 3 is a drawing showing forming processes of an I-shaped hairpin coil formed by a hairpin coil forming apparatus according to various disclosure.

[0063] The hairpin coil 1, as shown in FIG. 3, may be manufactured through a process of 3D forming head portion 4a of a coil material 3 formed in 2D in a previous process by the hairpin coil forming apparatus 100 according to various disclosure.

[0064] In the present specification, the reference direction for describing the components below is set as front and rear direction, left and right direction, and vertical direction when referring to the drawing.

[0065] In the present specification, the upper portion, upper end, or upper face of a component indicates an end portion, section, or face of the component which is relatively higher in the drawing, and the lower portion, lower end, or lower face of a component indicates an end, section, section, or face of the component that is relatively lower in the drawing.

[0066] In the present specification, the term end of a component (e.g., one end portion or the other end, etc.) refers to an end portion of the component in any direction, and the term part or portion of a component (e.g., one end portion or the other end, etc.) refers to a portion of the component that includes that end.

[0067] The hairpin coil forming apparatus 100 according to various disclosure is configured to firstly 3D-form a head portion 4a of a coil material 3 as shown in FIG. 3, and secondarily 3D-form a head portion 6a of a pre-formed coil 5 that was first 3D-formed.

[0068] The firstly 3D forming process may be defined as a process of forming a step on the head portion 4a of the coil material 3, and the secondary 3D forming process may be defined as a process of forming a curved line portion of a predetermined curvature on the head portion 6a of the pre-formed coil 5.

[0069] In FIG. 3, drawing reference symbol 4b indicates a leg portion of coil material 3, and drawing reference symbol 6b indicates a leg portion of pre-formed coil 5.

[0070] The hairpin coil forming apparatus 100 according to various disclosure provides a structure configured for minimizing quality dispersion of the hairpin coil 1 by firstly and secondarily 3D forming of the head portion 4a of the coil material 3 using a mold.

[0071] The hairpin coil forming apparatus 100 according to various disclosure includes a frame 10, a first mold 20, a second mold 40, a first coil transfer unit 60, and a second coil transfer unit 80.

[0072] The coil material 3, the head portion 4a and the leg portion 4b of the coil material 3, the pre-formed coil 5, the head portion 6a and the leg portion 6b of the pre-formed coil 5, and the finally formed hairpin coil 1 mentioned below are referred to FIG. 3.

[0073] In various disclosure, the frame 10 is configured to mount various components as described below. The frame 10 is fixed to a floor 10a of the process work area (see FIG. 11) and may be one frame or two or more partitioned frames.

[0074] The frame 10 may include various auxiliary elements such as brackets, plates, blocks, rods, and barrier ribs that are designed to support various components.

[0075] However, since the various accessory elements described above are for mounting each component to be described below to the frame 10, in various disclosure, except in exceptional cases, the various accessory elements described above are collectively referred to as the frame 10.

[0076] In various disclosure, the first mold 20 is configured to firstly 3D mold the head portion 4a of the coil material 3. The first mold 20 may form a step of a predetermined shape on the head portion 4a of the coil material 3.

[0077] The first mold 20 is disposed on one side of frame 10 when the forward/backward direction (or length direction) of the frame 10 is used as a reference.

[0078] FIG. 4 is a perspective view exemplarily illustrating a first mold applied to a hairpin coil forming apparatus according to various disclosure, FIG. 5 is a front view exemplarily illustrating a first mold applied to a hairpin coil forming apparatus according to various disclosure, and FIG. 6 is a side view showing a first mold applied to a hairpin coil forming apparatus according to various disclosure.

[0079] Referring to FIG. 4, FIG. 5, and FIG. 6, the first mold 20 according to various disclosure includes a first lower holder 21, a first coil guider 23, a first lower die 25, a first upper holder 27, a first upper die 29, and a head portion clamper 31.

[0080] The first lower holder 21 is fixed to the upper surface of the frame 10. The first lower holder 21 is disposed in block form.

[0081] The first coil guider 23 is configured to guide the coil material 3 toward the first lower die 25, which will be described later. The first coil guider 23 may guide the leg portion 4b of the coil material 3 toward the first lower die 25 along the left and right direction.

[0082] The first coil guider 23 is disposed on the first lower holder 21. The first coil guider 23 includes a pair of first guide blocks 24 which are disposed in parallel and secured to the first lower holder 21 at a predetermined spacing. The leg portion 4b of the coil material 3 may be guided along the clearance between the first guide blocks 24.

[0083] The first lower die 25 is configured to support the head portion 4a of the coil material 3. The first lower die 25 is disposed in the first lower holder 21 at a position corresponding to the first coil guider 23.

[0084] The first lower die 25 may include a pair of first lower forming steels 26 secured to the first lower holder 21.

[0085] The head portion 4a of the coil material 3 may be seated on one of the first lower forming steels 26 depending on the loading posture (settlement position and direction) of the coil material 3.

[0086] The first upper holder 27 is disposed to be movable in the vertical direction by operation of a first driver 28 at a position corresponding to the first lower die 25. The first driver 28 is disposed in a first mount block 33 which is disposed along the vertical direction on the first lower holder 21.

[0087] The first upper holder 27 is operationally connected to the first driver 28 along the vertical direction. The first driver 28 may, in one example, include a pneumatic cylinder.

[0088] The first upper die 29 is combined with the first lower die 25 along the vertical direction and is configured to form the head portion 4a of the coil material 3 disposed on the first lower die 25 into a predetermined shape.

[0089] The first upper die 29 is disposed in the first upper holder 27 at a position corresponding to the first lower die 25.

[0090] The first upper die 29 may include a pair of first upper forming steels 35 secured to the first upper holder 27.

[0091] The head portion clamper 31 is configured to clamp the head portion 4a of the coil material 3 disposed on the first lower die 25 along the vertical direction. The head portion clamper 31 is disposed on the first upper die 29.

[0092] FIG. 7 is a partially cut-away perspective view exemplarily illustrating a head clamper of a first mold applied to a hairpin coil forming apparatus according to various disclosure.

[0093] The head portion clamper 31, as shown in FIG. 7, includes at least one head portion clamping block 39 which is elastically supported by a spring 37 on the first upper die 29 and is configured for moving in the vertical direction.

[0094] The at least one head portion clamping block 39 may be disposed on the first upper forming steels 35 at positions corresponding to the first lower forming steels 26 of the first lower die 25, respectively.

[0095] At least one head portion clamping block 39 may be disposed on a guide rod 38 fixed to the inside of the first upper die 29 to be movable in the vertical direction by a predetermined stroke. The spring 37 is disposed inside the first upper die 29 and is configured to exert elastic force on at least one head portion clamping block 39.

[0096] Referring to FIG. 1 and FIG. 2, in various disclosure, the second mold 40 is configured to secondarily 3D-form the head portion 6a of the pre-molded coil 5, which is firstly formed by the first mold 20. The second mold 40 may form a curved line section on the head portion 6a of the pre-molded coil 5.

[0097] The second mold 40 is disposed on the other side of frame 10, with the forward/backward direction (or length direction) of the frame 10 as a reference.

[0098] FIG. 8 is a perspective view exemplarily illustrating a second mold applied to a hairpin coil forming apparatus according to various disclosure, FIG. 9 is a front view exemplarily illustrating a second mold applied to a hairpin coil forming apparatus according to various disclosure, and FIG. 10 is a side view exemplarily illustrating a second mold applied to a hairpin coil forming apparatus according to various disclosure.

[0099] Referring to FIG. 8, FIG. 9 and FIG. 10, the second mold 40 according to various disclosure includes a second lower holder 41, a second coil guider 43, a second lower die 45, a second upper holder 47, a second upper die 49, and a leg portion clamper 51.

[0100] The second lower holder 41 is fixed to the upper surface of frame 10. The second lower holder 41 is disposed in block form.

[0101] The second coil guider 43 is configured to guide the pre-formed coil 5 toward the second lower die 45, which will be described later. The second coil guider 43 may guide the leg portion 6b of the pre-forming coil 5 toward the second lower die 45 along the left and right direction.

[0102] The second coil guider 43 is disposed on the second lower holder 41. The second coil guider 43 includes a pair of second guide blocks 44 which are disposed in parallel and are secured to the second lower holder 41 at a predetermined spacing. The leg portion 6b of the pre-formed coil 5 may be guided along the clearance between the second guide blocks 44.

[0103] The second lower die 45 is configured to support the head portion 6a of the pre-formed coil 5. The second lower die 45 is disposed in the second lower holder 41 at a position corresponding to the second coil guider 43.

[0104] The second lower die 45 may include a pair of second lower forming steels 46 secured to the second lower holder 41.

[0105] The head portion 6a of the pre-forming coil 5 may be seated on one of the second lower forming steels 46 depending on the loading attitude of the pre-forming coil 5.

[0106] The second upper holder 47 is disposed to be movable in the vertical direction by operation of a second driver 48 at a position corresponding to the second lower die 45. The second driver 48 is disposed in a second mount block 53 disposed along the vertical direction on the second lower holder 41.

[0107] The second upper holder 47 is operationally connected to the second driver 48 along the vertical direction. The second driver 48 may, in one example, include a pneumatic cylinder.

[0108] The second upper die 49 is combined with the second lower die 45 along the vertical direction and is configured to form the head portion 6a of the pre-formed coil 5 disposed on the second lower die 45 into a predetermined shape.

[0109] The second upper die 49 is disposed in the second upper holder 47 at a position corresponding to the second lower die 45.

[0110] The second upper die 49 may include a pair of second upper forming steels 55 secured to the second upper holder 47.

[0111] The leg portion clamper 51 is configured to clamp the leg portion 6b of the pre-formed coil 5 disposed on the second coil guider 43 along the vertical direction. The leg portion clamper 51 is disposed to be movable in the vertical direction on the second upper holder 47.

[0112] The leg portion clamper 51 includes a leg portion clamping block 57 and a leg pusher 59.

[0113] The leg portion clamping block 57 is operationally connected to a clamp cylinder 52 disposed in the second upper holder 47. The leg portion clamping block 57 may be moved in the vertical direction by operation of the clamp cylinder 52 at a position corresponding to the second coil guider 43. In one example, the clamp cylinder 52 may include a pneumatic cylinder.

[0114] The leg pusher 59 is configured to pressurize the leg portion 6b of the pre-formed coil 5 along the vertical direction between the second guide blocks 44 of the second coil guider 43.

[0115] The leg pusher 59 extends protrudingly from the lower portion of the leg portion clamping block 57. The leg pusher 59 may pressurize the leg portion 6b of the pre-formed coil 5 by being inserted into the clearance space between the second guide blocks 44 by the leg portion clamping block 57.

[0116] Referring to FIG. 1 and FIG. 2, in various disclosure, the first coil transfer unit 60 is configured to transfer the 2D formed coil material 3 along a predetermined transfer path to the first mold 20.

[0117] FIG. 11 is a side view exemplarily illustrating a hairpin coil forming apparatus according to various disclosure.

[0118] Referring to FIG. 11, the first coil transfer unit 60 is disposed on the floor 10a of the process work area via base plate 61.

[0119] FIG. 12 is a perspective view exemplarily illustrating a first coil transfer unit applied to a hairpin coil forming apparatus according to various disclosure, and FIG. 13 is a side view exemplarily illustrating a first coil transfer unit applied to a hairpin coil forming apparatus according to various disclosure.

[0120] Referring to FIG. 11, FIG. 12, and FIG. 13, the first coil transfer unit 60 according to various disclosure includes a first horizontal moving member 63, a first vertical moving member 65, and a first coil gripper 67.

[0121] The first horizontal moving member 63 is disposed on the base plate 61 to be configured to move in the horizontal direction (e.g., left and right direction) at a position corresponding to the first mold 20.

[0122] The first horizontal moving member 63 is operationally connected to a first actuator 69 disposed on the base plate 61. The first horizontal moving member 63 may be moved in the horizontal direction by operation of the first actuator 69.

[0123] In one example, the first actuator 69 may include a first servo motor 71. The first servo motor 71 may be a motor configured for servo control of rotation speed and rotating direction.

[0124] The first horizontal moving member 63 is screw-connected to a conventional lead screw connected to the first servo motor 71 and may be slidably connected to a first guide device 72 disposed on the base plate 61 along the horizontal direction. The first horizontal moving member 63 may be moved in the horizontal direction along the first guide device 72 by rotation of the lead screw.

[0125] Alternatively, the first actuator 69 may include an operation cylinder, such as a pneumatic cylinder.

[0126] The first vertical moving member 65 is operationally connected to a second actuator 73 disposed on the first horizontal moving member 63. The first vertical moving member 65 may be moved in the vertical direction by operation of the second actuator 73.

[0127] In one example, the second actuator 73 may include a second servo motor 74. The second servo motor 74 may be a motor configured for servo control of rotation speed and rotating direction.

[0128] The first vertical moving member 65 is screw coupled with a conventional lead screw connected to the second servo motor 74 and may move in the vertical direction along a second guide device 75 disposed on the first horizontal moving member 63. The first vertical moving member 65 may be moved in the vertical direction along the second guide device 75 by rotation of the lead screw.

[0129] Alternatively, the second actuator 73 may include an operation cylinder, such as a pneumatic cylinder.

[0130] The first coil gripper 67 is configured to grip or un-grip the leg portion 4b of the coil material 3. The first coil gripper 67 is disposed on the first vertical moving member 65.

[0131] The first coil gripper 67 is operationally connected to a first gripping cylinder 68 disposed on the first vertical moving member 65. In one example, the first gripping cylinder 68 may include a pneumatic cylinder.

[0132] The first coil gripper 67 may include a pair of first gripping fingers 77 that are moved closer to or further away from each other along the vertical direction by operation of the first gripping cylinder 68.

[0133] Referring to FIG. 1 and FIG. 2, in various disclosure, the second coil transfer unit 80 is configured to transfer the pre-molded coil 5, which is firstly molded by the first mold 20, from the first mold 20 to the second mold 40 along a predetermined transfer path.

[0134] The second coil transfer unit 80 is disposed on the frame 10.

[0135] FIG. 14 is a perspective view exemplarily illustrating a second coil transport unit applied to a hairpin coil forming apparatus according to various disclosure, and FIG. 15 is a front view exemplarily illustrating a second coil transfer unit applied to a hairpin coil forming apparatus according to various disclosure.

[0136] Referring to FIG. 14 and FIG. 15, the second coil transfer unit 80 according to various disclosure includes a second horizontal moving member 81, a second vertical moving member 83, a second coil gripper 85, and a turning cylinder 87.

[0137] The second horizontal moving member 81 is disposed along the section between the first mold 20 and the second mold 40 in frame 10 to be configured to move in the horizontal direction (e.g., back-and-forth direction).

[0138] The second horizontal moving member 81 is operationally connected to a third actuator 89 disposed in the frame 10. The second horizontal moving member 81 may be moved in the horizontal direction by operation of the third actuator 89.

[0139] In one example, the third actuator 89 may include a third servo motor 91. The third servo motor 91 may be a motor configured for servo control of rotation speed and rotating direction.

[0140] The second horizontal moving member 81 is screw-connected to a conventional lead screw connected to the third servo motor 91 and may be slidably connected to a third guide device 92 disposed on the frame 10 along the horizontal direction. The second horizontal moving member 81 may be moved in the horizontal direction along the third guide device 92 by rotation of the lead screw.

[0141] Alternatively, the third actuator 89 may include an operation cylinder, such as a pneumatic cylinder.

[0142] The second vertical moving member 83 is operationally connected to a fourth actuator 93 disposed on the second horizontal moving member 81. The second vertical moving member 83 may be moved in the vertical direction by operation of the fourth actuator 93.

[0143] In one example, the fourth actuator 93 may include an operating cylinder 94. In another example, the operating cylinder 94 may include a pneumatic cylinder.

[0144] The second coil gripper 85 is configured to grip or un-grip the leg portion 6b of the preformed coil 5. The second coil gripper 85 is disposed on the second vertical moving member 83.

[0145] The second coil gripper 85 is operationally connected to a second gripping cylinder 86 disposed on the second vertical moving member 83. In one example, the second gripping cylinder 86 may include a pneumatic cylinder.

[0146] The second coil gripper 85 may include a pair of second gripping fingers 97 that are moved closer to or further away from each other along the vertical direction by operation of the second gripping cylinder 86.

[0147] The turning cylinder 87 is configured to rotate the second coil gripper 85 along the forward and backward direction.

[0148] The turning cylinder 87 is disposed on the second vertical moving member 83 and is operationally connected to the second coil gripper 85. The turning cylinder 87 may, in one example, include a pneumatic cylinder.

[0149] The second coil gripper 85 may rotate in the forward and backward direction by operation of the turning cylinder 87.

[0150] Accordingly, the second coil gripper 85 may rotate in one direction by operation of the turning cylinder 87 and grip the pre-molded coil 5 on the first mold 20 side thereof.

[0151] And, the second coil gripper 85 may load the pre-molded coil 5 into the second mold 40 by rotating in the other direction by operation of the turning cylinder 87.

[0152] That is, the turning cylinder 87 rotates the second coil gripper 85 along the forward and backward direction, and may change the coil gripping position of the second coil gripper 85.

[0153] FIG. 16 and FIG. 17 are drawings for explaining the operation of a hairpin coil forming apparatus according to various disclosure.

[0154] Hereinafter, the operation of the hairpin coil forming apparatus 100 according to various disclosure configured as described above will be described in detail referring to FIG. 1 FIG. 17.

[0155] In various disclosure, the 2D formed coil material 3 is disposed in a previous process. The coil material 3 may be transferred to the first coil transfer unit 60 of the hairpin coil forming apparatus 100 according to various disclosure, for example, by a robot gripper.

[0156] In the hairpin coil forming apparatus 100 according to various disclosure, the first upper holder 27 of the first mold 20 is moved upward together with the first upper die 29 by operation of the first driver 28, and the second upper holder 47 of the second mold 40 is moved upward together with the second upper die 49 by operation of the second driver 48.

[0157] In the present state, the coil material 3 transferred by the robot gripper is gripped by the first coil gripper 67 of the first coil transfer unit 60 by operation of the first gripping cylinder 68.

[0158] Accordingly, the first coil gripper 67 moves along the vertical direction to a predetermined height by operation of the second actuator 73, and moves toward the first mold 20 along the horizontal direction (e.g., left and right direction) by operation of the first actuator 69. The coil material 3 is transported along the first coil guider 23 of the first mold 20.

[0159] Next, when the head portion 4a of the coil material 3 is disposed on the first lower die 25, the first coil gripper 67 un-grip s the coil material 3 by operation of the first gripping cylinder 68.

[0160] Accordingly, the head portion 4a of the coil material 3 is loaded into one of the first lower forming steels 26 of the first lower die 25. Accordingly, the first coil gripper 67 grips the coil material 3 again by operation of the first gripping cylinder 68.

[0161] In the present state, the first upper holder 27 of the first mold 20 moves downward together with the first upper die 29 by operation of the first driver 28.

[0162] Accordingly, as shown in FIG. 16, the first upper forming steels 35 of the first upper die 29 are joined with the first lower forming steels 26 of the first lower die 25. Therefore, the first lower forming steels 26 and the first upper forming steels 35 3D form the head portion 4a of the coil material 3 into a predetermined shape.

[0163] In the above process, the head portion clamper 31 of the first mold 20 clamps the head portion 4a of the coil material 3. At the instant time, at least one head portion clamping block 39 of the head portion clamper 31 overcomes the elastic force of the spring 37 and moves upward to clamp the head portion 4a of the coil material 3 by the elastic force of the spring 37.

[0164] Here, the first coil gripper 67 grips the coil material 3, the head portion clamper 31 clamps the head portion 4a of the coil material 3, and the leg portion 4b of the coil material 3 is disposed on the first coil guider 23, so that the first lower forming steels 26 and the first upper forming steels 35 can firstly 3D form the head portion 4a.

[0165] Accordingly, the hairpin coil forming apparatus 100 according to various disclosure may prevent distortion of the position of the coil material 3 and deformation of the leg portion 4b when firstly 3D forming the coil material 3.

[0166] Next, the second coil gripper 85 of the second coil transfer unit 80 rotates in one direction by operation of the turning cylinder 87 and moves along the vertical direction to a predetermined height by operation of the fourth actuator 93.

[0167] In the present state, the second coil gripper 85 moves toward the first mold 20 along the horizontal direction (e.g., back-and-forth direction) by operation of the third actuator 89.

[0168] And, the second coil gripper 85 grips the pre-molded coil 5, which is firstly molded in the first mold 20, by operation of the second gripping cylinder 86. At the same time, the first coil gripper 67 of the first coil transfer unit 60 un-grip s the pre-formed coil 5 by operation of the first gripping cylinder 68.

[0169] Next, the second coil gripper 85 is rotated in the other direction by operation of the turning cylinder 87 and moves toward the second mold 40 in the forward and backward direction by operation of the third actuator 89.

[0170] Accordingly, when the second coil gripper 85 moves in the vertical direction to a predetermined height by operation of the fourth actuator 93, the leg portion 6b of the pre-molded coil 5 is disposed between the second guide blocks 44 of the second coil guider 43 of the second mold 40.

[0171] In the present state, the second coil gripper 85 un-grips the pre-molded coil 5 by operation of the second gripping cylinder 86. Accordingly, the head portion 6a of the pre-molded coil 5 is loaded into one of the second lower forming steels 46 of the second lower die 45. Accordingly, the second coil gripper 85 grips the pre-molded coil 5 again by operation of the second gripping cylinder 86.

[0172] Accordingly, the second upper holder 47 of the second mold 40 moves downward together with the second upper die 49 by operation of the second driver 48.

[0173] Accordingly, as shown in FIG. 17, the second upper forming steels 55 of the second upper die 49 are joined with the second lower forming steels 46 of the second lower die 45. Therefore, the second lower forming steels 46 and the second upper forming steels 55 3D form the head portion 6a of the pre-molded coil 5 into a predetermined shape.

[0174] In the above process, the leg portion clamping block 57 of the leg portion clamper 51 of the second mold 40 moves in the downward direction by operation of the clamp cylinder 52.

[0175] Accordingly, the leg pusher 59 of the leg portion clamper 51 pressurizes and clamps the leg portion 6b of the pre-molded coil 5 between the second guide blocks 44 of the second coil guider 43.

[0176] While the second coil gripper 85 grips the pre-molded coil 5 and the leg portion 6b of the pre-molded coil 5, which is disposed between the second guide blocks 44, is clamped by the leg portion clamper 51, the second lower forming steels 46 and the second upper forming steels 55 may secondarily 3D-form the head portion 6a of the pre-molded coil 5.

[0177] Accordingly, the hairpin coil forming apparatus 100 according to various disclosure may prevent distortion of the posture (or position distortion) of the pre-molded coil 5 and deformation of the leg portion 6b when secondarily 3D forming the pre-molded coil 5.

[0178] Therefore, the hairpin coil forming apparatus 100 according to various disclosure can form an I-type hairpin coil 1 by repeating a series of processes as described above.

[0179] The hairpin coil forming apparatus 100 according to various disclosure described so far can firstly 3D-form the head portion 4a of the I-shaped coil material 3 that has been 2D-formed in a previous process using the first mold 20, and secondarily 3D-form the head portion 6a of the pre-molded coil 5 that has been 3D-formed by the first mold 20.

[0180] Furthermore, the hairpin coil forming apparatus 100 according to various disclosure can perform 3D molding while stably supporting the coil material 3 in the first mold 20 and 3D molding while stably supporting the pre-molded coil 5 in the second mold 40.

[0181] Therefore, the hairpin coil forming apparatus 100 according to various disclosure can minimize the quality dispersion of the I-type hairpin coil 1 by preventing the misalignment and deformation of the leg portions 4b and 6b during 3D forming of the coil material 3 and the pre-molded coil 5.

[0182] Accordingly, according to the hairpin coil forming apparatus 100 according to various disclosure, the forming quality of the hairpin coil 1 may be improved, the repetitive forming precision of the hairpin coil 1 may be improved, and the productivity of the hairpin coil 1 may be improved.

[0183] Although various disclosure of the present disclosure have been described above, the technical idea of the present disclosure is not limited to the exemplary embodiment presented in the present specification, and a person skilled in the art who understands the technical idea of the present disclosure may easily propose another exemplary embodiment of the present disclosure by adding, changing, deleting, or adding components within the scope of the same technical idea, and this will also fall within the scope of the rights of the present disclosure.